The torch holder was designed for self-alignment, easy installation, and easy manufacturability. The team designed the part so that it is offset at an angle that would place the torch tip perpendicular to the surface of the test specimen. 

The U-Bolt holes are required in order to keep the oxy-acetylene torch from slipping and rotating. The rail mounting holes were designed to line up with the two rail slots from the aluminum extrusion frame. The torch tip offset is with respect to the rails, so the base of the torch holder must be in line with the rails it is mounted on.  

Photo of the torch mounted on the first iteration torch holder. The team decided aesthetics are important and the design can be cleaned up and requested a second iteration. 

The second iteration of the torch holder reduces the height of the base and uses two screws for alignment. The design also cuts out excess material where the torch sits. This is partly due to the fact that there will be an insignificant amount of loading on the torch in all directions. 

The linear actuator adapter's purpose is to integrate the ball-screw's carriage with the specimen holder assembly. It was also made to hold the 1-inch insulation block that is meant to keep the electronics shielded from intense heat. 

"Rose Petals" were added to give a platform for the insulation to sit on. Additionally, the holes that bolt into the carriage were widened to accommodate the hex head bolts. 

This is a photo of the 3D printed rose petal design. The 3D print includes 4 walls of filament making it very strong for its application. The issue the team had was determining if the 3D printed part would melt as the aluminum extrusion conducted heat from the 3,600 C torch flame. 

In order to remove the worry of melting parts, the team designed a new specimen holder adapter. It consists of a flat plate to attach two gussets and holes for bolting into the new belt drive. This allows any 1-inch piece of aluminum extrusion to be installed as needed. 

Extensive work has gone into programming the Oxy-Acetylene ablation test stand. The first task was to power, activate, and control the ball-screw rail. Once that was completed, the team worked to find a new method of moving the specimen holder. The team settled on a belt drive from an Ender 3 3D printer as it was a lot quicker than the ball screw. 

Stepper Motor Driven Linear Actuator 

Linear Actuator & Kill Switch Circuitry

With the proof of concept completed and working as intended, the team worked to create a housing and incorporate valves and limit switches on the project. 

Control Box Design Iterations 

PCB Design